Multi-mode portable lighting device

ABSTRACT

A portable lighting device, such as a flashlight, with a mechanical power switch and multiple operating modes is provided. The mechanical power switch is disposed in series with the controller for the lighting device and acts as the user interface to the controller to change modes of operation. Because the mechanical power switch is in series with the controller, the portable lighting device does not consume battery power when the mechanical switch is open. A state machine coupled to the controller is polled by the controller each time it is powered up to determine the operational mode of the lighting device.

TECHNICAL FIELD

The present invention relates to portable lighting devices, including,for example, flashlights, lanterns and head lamps, and their circuitry.

BACKGROUND

Various hand held or portable lighting devices, including flashlights,are known in the art. Such lighting devices typically include one ormore dry cell batteries having positive and negative electrodes. Thebatteries are arranged electrically in series or parallel in a batterycompartment or housing. The battery compartment is also sometimes usedto hold the lighting device, particularly in the case of flashlights. Anelectrical circuit is established from a battery electrode throughconductive means which are electrically coupled with an electrode of alight source, such as a lamp bulb or a light emitting diode (“LED”).After passing through the light source, the electric circuit continuesthrough a second electrode of the light source in electrical contactwith conductive means, which in turn are in electrical contact with theother electrode of a battery. The circuit includes a switch to open orclose the circuit. Actuation of the switch to close the electricalcircuit enables current to pass through the lamp bulb, LED, or otherlight source—and through the filament, in the case of an incandescentlamp bulb—thereby generating light.

Flashlights and other portable lighting devices have conventionallyemployed a mechanical power switch in the main power circuit of theflashlight to turn “on” the flashlight and turn “off” the flashlight.When the user desired to turn “on” the flashlight, the user manipulatedthe mechanical power switch to mechanically connect two contacts toclose the switch and complete the power circuit, thereby allowingcurrent to flow from the positive terminal of the batteries, through thelight source, and back to the negative terminal of the batteries. Whenthe user desired to turn “off” the flashlight, the user manipulated themechanical switch to disconnect the two contacts of the switch andthereby open the switch and break the power circuit. The mechanicalswitch in such devices, therefore, acts as a conductor in completing thepower circuit and conducting current throughout the operation of theportable lighting device.

A variety of mechanical switch designs are known in the art, including,for example, push button switches, sliding switches, and rotating headswitches. Such switches tend to be fairly intuitive and easy to operateby the user. However, portable lighting devices having just a simplemechanical power switch do not include automated operating modes, suchas, for example, a blink mode, a power reduction mode, or an SOS mode.To include such automated functionality in a portable lighting device,the portable lighting device must have advanced electronics.

For example, multi-mode electronic flashlights and other portablelighting devices have been designed using an electronic power switchcontrolled by a processor of a microchip or microcontroller. In suchlighting devices, the various modes that are programmed into themicrochip are selected through the appropriate manipulation of a userinterface, such a momentary switch.

In one approach, the electronics of the multi-mode portable lightingdevice remain constantly connected to the power source. As a result,however, the electronics constantly consume power, thereby decreasingthe useful battery life, or in the case of rechargeable batteries, theoperational time between charges.

In another approach, a mechanical power switch, which is disposedelectrically in series with the light source and controller, is used tosimultaneously break the circuit powering the electronics and the lightsource. As a result, the electronics do not consume power from thebatteries (or battery) when the portable lighting device is turned off.However, in order for the mechanical power switch to be used as the userinterface to select different modes of operation by, for example,opening and then closing the mechanical power switch within a definedperiod of time, the microchip is provided with an alternative source oftemporary power.

The alternative source of temporary power is provided so that when themechanical power switch is opened the microchip will remain temporarilypowered, even though the portable lighting device has been shut off,until the mechanical power switch is again closed. In the absence of thealternative source of temporary power, the microchip would lose powerwhen the mechanical power switch is opened, causing the controller toreset and return to its default mode of operation the next time themechanical power switch is closed instead of toggling to the nextoperational mode.

One or more capacitors arranged in parallel with the controller havebeen used as the alternative source of power. The capacitors areselected to have sufficient capacitance to power the controller for asuitable period of time, such as one to two seconds, following theopening of the mechanical power switch before falling below the resetvoltage of the controller. Thus, as long as the mechanical power switchis again closed within the allotted time frame, the lighting device willbegin to operate in the next mode of operation.

A disadvantage of this approach is that significant capacitance isrequired to be able to power the controller for an adequate period oftime, resulting in increased cost. In addition, in some configurations,the required capacitor(s) may have a physical foot print that is largerthan the amount of space available on the printed circuit board to beincluded in the portable lighting device.

SUMMARY

An object of the present patent document is to provide a multi-modeportable lighting device that uses a mechanical power switch as the userinterface and that addresses, or at least ameliorates, on or more of theproblems associated with the multi-mode portable lighting devicesdiscussed above.

Accordingly, in a first aspect, a multi-mode portable lighting device,such as a flashlight, with multiple modes of operation is provided. Theportable lighting device is operated by a mechanical power switch.Actuation of this switch powers on and off the portable lighting device.It is also used to select the mode of operation. In one embodiment,there are no other switches, inputs, or any other man to machineinterface other than the single mechanical power switch. At anytime whenthe mechanical power switch is in the off (or open) position, allcircuitry is physically disconnected from the battery and no batterycurrent is consumed. The lighting device may include a number of modesof operation and the modes of operation may include, for example, anormal mode, one or more power save modes, a flash mode, a SOS mode,etc.

According to one embodiment, the multi-mode portable lighting devicecomprises a housing for receiving a portable power source having apositive electrode and a negative electrode, a light source having afirst electrode and a second electrode, and a main power circuit forconnecting the first and second electrodes of the light source to thepositive and negative electrodes of the portable power source,respectively. The main power circuit includes a mechanical power switchand an electronic power switch disposed electrically in series with thelight source. The portable lighting device further comprises acontroller electrically coupled in series with the mechanical powerswitch so that when the mechanical power switch is opened, thecontroller is not powered by the portable power source. The controllerincludes an output for providing a control signal for controlling theopening and closing of the electronic power switch, and the controlleris configured to control the electronic power switch in a manner toprovide at least two modes of operation. A state machine having a memorymechanism for temporarily storing a mode of operation and at least oneoutput coupled to the controller for communicating at least one outputsignal to the controller is also included in the portable lightingdevice. Further, the controller is configured to determine the mode ofoperation based on at least one output signal from the state machine atpower up and then to write a new mode of operation to the state machine.

According to another aspect, a method of operating a multi-mode portablelighting device including a main power circuit for connecting a lightsource to a portable power source and a controller for controlling anelectronic power switch disposed in the main power circuit which is inelectrical series with the light source, wherein the controller iselectrically connected in series to a mechanical power switch disposedin the main power circuit in series with the light source and which actsas the user interface to the controller. The method comprises the stepsof: using the controller at power up to read at least one output signalfrom a state machine to determine a first mode of operation based on theat least one output signal; and writing a second mode of operation fromthe controller to the state machine following power up, wherein thestate machine remembers the second mode of operation for a brief periodafter the mechanical power switch is opened so that if the mechanicalpower switch is closed before the brief period lapses, the controllerwill operate in the second mode of operation. Preferably the briefperiod is long enough for a user to reliably open and close themechanical power switch without undue difficulty. Typically a period ofabout 1.5 seconds should be adequate.

According to another aspect, a method of calibrating one or more memorycapacitors of a driver circuit for a multi-mode portable lighting deviceis provided, wherein each memory capacitor is connected to a data portof a controller in parallel with a bleed off resistor. The methodaccording to one embodiment comprises powering the driver circuit tocharge each of the one or more memory capacitors, removing the powerfrom the driver circuit for a predetermined time interval, powering thedriver circuit as soon as the predetermined time interval has lapsed,and measuring the voltage value on each of the one or more memorycapacitors; and storing the voltage measured for each of the one or morememory capacitors in a non-volatile memory accessible by the controller.

Further aspects, objects, desirable features, and advantages of theinvention will be better understood from the following descriptionconsidered in connection with accompanying drawings in which variousembodiments of the disclosed invention are illustrated by way ofexample. It is to be expressly understood, however, that the drawingsare for the purpose of illustration only and are not intended as adefinition of the limits of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a flashlight according to an embodimentof the present patent document.

FIG. 2 is a cross-sectional view of the flashlight of FIG. 1 takenthrough the plane indicated by 2-2.

FIG. 3 is an enlarged cross-sectional side view of the front end of theflashlight of FIG. 1 as taken through the plane indicated by 2-2 wherethe flashlight is shown in the OFF position.

FIG. 4 is a cross-sectional view of the LED module of the flashlight ofFIG. 1.

FIG. 5A is a side view of a retaining collar, and FIG. 5B is alongitudinal cross-sectional view through the retaining collar.

FIG. 6 is an embodiment of a circuit diagram for the flashlight of FIG.1.

FIG. 7 is a circuit diagram according to one embodiment of a statemachine for the flashlight of FIG. 1.

FIG. 8 is another embodiment of a circuit diagram for the flashlight ofFIG. 1.

FIG. 9 is a circuit diagram of one embodiment of a regulating circuitfor use in the circuit of FIG. 8.

DETAILED DESCRIPTION

A multi-mode flashlight 10 according to an embodiment is illustrated inperspective in FIG. 1. The flashlight 10 incorporates a number ofdistinct aspects. While these distinct aspects have all beenincorporated into the flashlight 10, it is to be expressly understoodthat the invention is not restricted to flashlight 10 described herein.Rather, the inventive features of the flashlight 10 described below,both individually as well as in combination, all form a part of theinvention. Further, as will become apparent to those skilled in the artafter reviewing the present disclosure, one or more aspects of thepresent invention may also be incorporated into other portable lightingdevices, including, for example, head lamps and lanterns.

Referring to FIG. 1, the flashlight 10 includes a head assembly 20, abarrel 12, and a tail cap assembly 30. The head assembly 20 is disposedabout the forward end of the barrel 12. The tail cap assembly 30encloses the aft end of the barrel 12.

FIG. 2 is a cross-sectional view of the flashlight of FIG. 1 takenthrough the plane indicated by 2-2. FIG. 3 is an enlargedcross-sectional side view of the front end of the flashlight of FIG. 1as taken through the plane indicated by 2-2. The flashlight is shown inthe OFF position in FIGS. 2-3.

Referring to FIGS. 2 and 3, a light source 14 is mounted to the forwardend of the barrel 12. In the present embodiment, the light source 14 ismounted so that it is disposed at the aft end of reflector 106. In otherembodiments, the reflector 106 may be omitted, or its shape changed.

The barrel 12 is a hollow, tubular structure suitable for housing aportable power source, such as, for example, one or more batteries 16.Thus, the barrel 12 serves as a housing for receiving a portable powersource having a positive and a negative electrode.

In the illustrative embodiment, barrel 12 is sized to accommodate twobatteries 16 disposed in a series arrangement. The batteries arepreferably alkaline type dry cell batteries of a AA size in the presentembodiment. However, rechargeable batteries may be used instead of drycell batteries. In addition, batteries having sizes other than AA may beused.

The barrel 12 may also be configured to include a single battery, threebatteries, or a plurality of more than three batteries arranged ineither a series or a side-by-side arrangement. Other suitable portablepower sources, including, for example, high capacity storage capacitors,may also be used.

In the illustrated embodiment, the barrel 12 includes forward threads 18formed on the outer diameter of its front end, and aft threads 22 formedon the inside diameter of its aft end. The barrel 12 of the presentembodiment also includes an annular lip 24 of reduced diameterprojecting from the inner diameter of the barrel at a forward end. Anaft facing surface of the annular lip 24 forms a contact 21 for amechanical power switch described below.

Referring to FIG. 2, the tail cap assembly 30 includes a tail cap 28 anda conductive spring member 32. The tail cap 28 preferably includes aregion of external threads 34 for engaging the matching aft threads 22formed on the interior of the barrel 12. Other suitable means may alsobe employed for attaching the tail cap 28 to the barrel 12.

A sealing element 36 may be provided at the interface between the tailcap 28 and the barrel 12 to provide a watertight seal. The sealingelement 36 may be an O-ring or other suitable sealing devices. In theillustrated embodiment, the sealing element 36 is a one-way valve formedby a lip seal that is orientated so as to prevent flow from the outsideinto the interior of the flashlight 10, while simultaneously allowingoverpressure within the flashlight to escape or vent to the atmosphere.Radial spines may be disposed at the interface 35 between the tail cap28 and the barrel 12 to ensure that the end of the barrel 12 does notprovide a gas tight seal against the adjacent flange of the tail cap 28,thereby impeding the flow of overpressure gases from the interior of theflashlight.

The design and use of one-way valves in flashlights are more fullydescribed in U.S. Pat. No. 5,003,440 issued to Anthony Maglica, which ishereby incorporated by reference.

In the present embodiment, barrel 12 and tail cap 28 are formed out ofmetal, preferably aircraft grade aluminum. Further, the barrel 12, tailcap 28, and conductive spring member 32 form part of the ground returnpath from a negative electrode of the light source 14. The conductivespring member 32 is electrically coupled to the case electrode of thebattery 16 and the tail cap 28. Tail cap 28 is in turn electricallycoupled to the barrel 12 through interface 35. Thus, when the tail capassembly 30 is installed in the barrel 12, the conductive spring member32 forms an electrical path between the case electrode of the battery 16and the tail cap 28, and the tail cap 28 forms an electrical pathbetween the conductive spring member 32 and the barrel 12 through, forexample, interface 35 and/or the mating threads 22, 34.

To facilitate the flow of electricity, any existing surface treatments,such as by anodizing, disposed at the tail cap/barrel contact and theinterface between conductive spring member 32 and tail cap 28 should beremoved.

In addition to acting as a conductor in the main power circuit, theconductive spring member 32 also urges the batteries 16 toward the frontof the flashlight 10. As a result, the center electrode of the rearbattery is in electrical contact with the case electrode of the nextforward battery. In this way, the batteries 16 contained in the barrel12 are electrically coupled. The center electrode of the forward-mostbattery 16 is urged into contact with a compressible positive contact 54of lighting module 40.

Referring to FIG. 3, the lighting module 40 is disposed at the forwardend of the barrel 12 and in the present embodiment, among other things,holds the light source 14 relative to a reflector 106 of the headassembly 20. The light source 14 includes a first, positive electrode inelectrical communication with the positive contact 54 via second circuitboard 58 and a second, negative electrode in electrical communicationwith the heat sink housing 44. The light source 14 may be any suitabledevice that generates light. For example, the light source 14 can be anLED lamp, an incandescent lamp, or an arc lamp. In the illustratedembodiment, the light source 14 is an LED lamp and lighting module 40 isan LED module. LED 37 of lighting module 40 preferably substantiallyradiates light at a spherical angle of less than 180°. In otherembodiments, LEDs with other angles of radiation may be used, includingLEDs that radiate at an angle greater than 180°.

The structure of an LED module that may be used for lighting module 40is described in detail in co-pending U.S. patent application Ser. No.12/188,201, which is hereby incorporated by reference.

Lighting module 40 together with the retaining collar 42, barrel 12, andhead assembly 20 form mechanical power switch corresponding tomechanical power switch 41 shown in the circuit diagram of FIG. 6. Thecontacts of the mechanical power switch 41 comprise the contact 21 ofthe annular region 24 and the heat sink housing 44 of the lightingmodule 40. In FIG. 3, the flashlight 10 is shown in the OFF condition(i.e., switch 41 is open). To close switch 41 and turn flashlight 10 ON,the head assembly is rotated in the counterclockwise direction relativeto the barrel so that the head assembly 20 is axially translated awayfrom the barrel and the heat sink housing 44 comes into contact withcontact 21, thereby closing the circuit of the flashlight 10 and turningthe flashlight 10 ON. To turn flashlight 10 OFF, the head assembly isrotated in the opposite, clockwise, direction so that the head assemblyis axially translated toward the barrel and pushes the heat sink housing44 of lighting module 40 out of contact with contact 21 of the barrel12.

FIG. 4 is a cross-sectional view of the lighting or LED module 40 inisolation. The LED module 40 of the present embodiment includes an LED37 as light source 14, a first circuit board 38, a lower assembly 45formed by compressible positive contact 54 and a lower insulator 56, asecond circuit board 58, an upper assembly 70 formed by an upperinsulator 72 and an upper positive contact 74 and an upper negativecontact (not shown), and a heat sink 80 formed by the outer heat sinkhousing 44 and a contact ring 81, which are preferably made out ofmetal.

For redundancy, the compressible positive contact 54 preferably includestwo clips 55 for making electrical contact with second circuit board 58,one of the clips 55 being displaced before the page in thecross-sectional view provided in FIG. 4. The second circuit board 58 isin electrical contact with upper positive contact 74 and an uppernegative or ground contact, which are preferably solder connected to thebottom side of the first circuit board 38. For redundancy, the upperpositive contact 74 preferably includes two clips 76, one of which isdisplaced before the page in the view provided in FIG. 4. The upperground contact also includes two clips 76 for making electrical contactwith the second circuit board 58, one of which is displaced behind theclip 76 of the upper positive contact shown in FIG. 4 and one of whichis displaced before the page in the view provided in FIG. 4. The upperpositive contact 74 is in electrical communication with the positiveelectrode of LED 37 via first circuit board 38 and the upper groundcontact is in electrical communication with the heat sink 80 via thefirst circuit board 38.

The LED 37 and the heat sink 80 are affixed to the first circuit board38, preferably via a solder connection. The first circuit board 38,which preferably is a metal clad circuit board having a plurality ofthermally conductive layers connected by thermal vias, promotes therapid and efficient transfer of heat from the LED 37 to the heat sink80.

The LED 37 can be any light emitting diode that can be soldered to aprinted circuit board. Preferably the LED 37 can be soldered to thefirst circuit board 38 using a screen applied solder paste and a reflowoven. More preferably, the LED 37 is the LUXEON® Rebel productcommercially available from Philips Lumileds Lighting Company, LLC.

The second circuit board 58 includes the circuitry for operatingflashlight 10 and making it function as a multi-mode flashlight.

The lower assembly 45 is preferably formed by co-molding compressiblepositive contact 54 and a lower insulator 56 together. Likewise, upperassembly 70 is preferably formed by co-molding upper insulator 72 and anupper positive contact 74 and an upper negative contact together. Thus,the upper and lower insulator are preferably formed from an injectionmoldable plastic with suitable structural and thermal qualities for theapplication.

The upper positive and negative contacts of the upper assembly 70 aresoldered to the bottom of the first circuit board 38, the front side ofwhich is in turn soldered to contact ring 81, which can be press fitand/or soldered to heat sink housing 44. Thus, the upper assembly 70 isfirmly held within heat sink housing 44 in the present embodiment.Further, the circumference of heat sink housing 44 is crimped into anannular recess 83 of the lower insulator 56. The crimping of heat sinkhousing 44 into annular recess 83 holds lower insulator 56 and hence thelower assembly 45 within heat sink housing 44.

When flashlight 10 is in the ON state, the heat sink housing 44thermally and electrically couples the light source 14 and the barrel12. In addition, the heat sink housing 44 electrically couples theground path of the second circuit board 58 to the barrel 12. The heatsink housing 44 therefore acts as the negative, or ground, contact forthe lighting module 40. Further, by arranging the heat sink housing 44as shown in FIG. 2 so that it is in good thermal contact with the barrel12 when the flashlight 10 is ON, heat that is generated by the lightsource 14 is efficiently absorbed and/or dissipated by the first circuitboard 38 to contact ring 81, the heat sink housing 44 and finally barrel12. Thus flashlight 10 is able to effectively protect the light source14 from being damaged due to heat. Preferably, the heat sink housing 44is made from a good electrical and thermal conductor, such as aluminum.

The heat sink housing 44 is formed so that it flares in a region 78toward the back or bottom of the LED module 40 from a first region 77having a first diameter to a second region 79 having a second, largerdiameter. The diameter of the first region 77 is sized so that it canfit within the annular lip 24 without coming in contact with the annularlip 24. The outer diameter of the lower insulator 56 is sized so thatthere is little or no play in the radial direction between the innerwall of the barrel and the lower insulator 56. In this way, the heatsink housing 44 can be kept from contacting the barrel 12 except whenLED module 40 is pushed far enough forward within barrel 12 so that theflared region 78 of the heat sink housing 44 comes into contact with thecontact 21 of the annular lip 24 of barrel 12.

The outer surface of the heat sink housing 44 also includes an annularrecess 82 in the region 77 of the first diameter. The annular recess 82is generally perpendicular to the axis of the heat sink and the barrel12. In addition, the annular recess 82 is positioned to receive lockingtabs 85 (see FIG. 5) of retaining collar 42 when the LED module 40 ismounted within the barrel 12.

The flared region 78 of the heat sink housing 44 is preferably shaped tomate with contact 21 along as much surface area as possible tofacilitate electrical and thermal communication between the LED module40 and the barrel 12. The flared region 78 of the heat sink housing 44is also sized so that once disposed in the barrel 12, the axial movementof the heat sink housing 44, and, consequently, the LED module 40, inthe forward direction will be limited by the annular lip 24 of thebarrel 12.

The lower insulator 56 includes at its back face 88 a recess 89, whichis surrounded by an annular shoulder 90 so that the recess is centrallylocated. The recess 89 is dimensioned to be deeper than the height ofthe center electrode of battery 16. However, as shown in FIGS. 2 and 3,when the forward most battery 16 is urged forward against the back face88 of the lower insulator 56, the center electrode of battery 16 engageswith the compressible positive contact 54. In this way, the LED module40 provides a simple configuration that enhances the electrical couplingbetween components even when the flashlight is jarred or dropped, whichmay cause the battery or batteries 16 to suddenly displace axiallywithin the barrel 12. Further, because the compressible positive contact54 may absorb impact stresses due to, for example, mishandling andrecess 89 is deeper than the center electrode of the forward mostbattery 16, the battery's center electrode and the electronics of theflashlight provided on second circuit board 58 are well protected fromphysical damage during use of the flashlight 10.

Also, because compressible positive contact 54 is disposed forward ofthe shoulder 90 of back face 88, if a battery or batteries 16 areinserted backwards into the barrel 12 so that their case electrodes aredirected forward, no electrical coupling with compressible positivecontact 54 is formed. Accordingly, the configuration of the LED module40 and its arrangement within barrel 12 will help to protect theflashlight's electronics from being affected or damaged by reversecurrent flow. In another embodiment, the electronics of flashlight 10are protected from reverse current flow by the use of a diode includedin the electrical circuit of the flashlight.

Referring to FIGS. 2 and 3, the lighting module 40 is disposed generallyin the forward end of the barrel 12. Absent further assembly, thelighting module 40 is urged forward by the action of the conductivespring member 32 on batteries 16 until the flared region 78 of the heatsink housing 44 comes into contact with the annular lip 24 of the barrel12. The retaining collar 42 attaches to the heat sink housing 44 of thelighting module 40 and, among other things, limits axial movement of thelighting module 40 in the rearward direction beyond a predetermineddistance. The retaining collar 42 attaches to the lighting module 40 atthe annular recess 82 of the heat sink housing 44.

Referring to FIGS. 3, 5A and 5B, the retaining collar 42 includescircumferential locking tabs 85, which project inwardly from the innersurface of the retaining collar 42, and ribs 86, which project outwardlyfrom the outer surface of the retaining collar 42. Referring to FIG. 3,each of the locking tabs 85 is sized to fit into the annular recess 82on the exterior of the heat sink housing 44. A plurality of ribs 86 arepreferable spaced equally around the exterior circumference of theretaining collar 42 so as to generally extend in the axial direction ofthe retaining collar 42. The ribs 86 preferably extend from the front ofthe retaining collar to slightly over half the axial length of retainingcollar 42. The ribs 86 are dimensioned so as to limit the amount ofradial play between the forward end of the lighting module 40 and theinner diameter of the barrel 12 to a desirable amount. The ribs 86 arealso preferably dimensioned to project outwardly from retaining collar42 by the same or a greater distance than the locking tabs 85 projectinwardly. By only having the ribs extend to about the middle of the ofthe retaining collar 42, the aft end 87 of the retaining collar 42 canexpand sufficiently over the outer surface of the heat sink housing 44within the barrel 12 until circumferential locking tabs 85 snap intoannular recess 82 (see FIG. 3). Once the circumferential locking tabs 85are snapped into annular recess 82, the rearward movement of thelighting module 40 is confined by the annular lip 24. Thus, by securingthe retaining collar 42 to the lighting module 40, which is disposed inthe barrel 12, the retaining collar 42 keeps the lighting module 40 fromfalling to the rear of barrel 12, and potentially out the back end ofthe flashlight 10, in the absence of batteries 16 being installed in theflashlight 10. In a preferred embodiment, the retaining collar 42 ismade from an insulator such as, for example, plastic.

Referring to FIG. 3, the head assembly 20 is disposed on the forward endof barrel 12. The head assembly 20 includes a face cap 102, a lens 104,a reflector 106, and a head 108. The reflector 106 and the lens 104 arerigidly held in place by the face cap 102, which is threadably coupledto the head 108. The head 108 includes threads 112 formed on its insidediameter that engage with the forward threads 18 of the barrel 12.Arranged this way, the reflector 106 may be displaced in the axialdirection of the flashlight 10 by rotating the head assembly 20 relativeto the barrel 12.

In a preferred implementation of the illustrated embodiment, the tailcap 28, the barrel 12, the face cap 102 and the head 108, generallyforming the external surfaces of the flashlight 10 are manufactured fromaircraft quality, heat treated aluminum, which may be selectivelyanodized. The non-conductive components are preferably made frompolyester plastic or other suitable material for insulation and heatresistance.

Referring back to FIG. 3, the reflective profile 118 of the reflector106 is preferably a segment of a computer-generated optimized parabolathat is metallized to ensure high precision optics. Optionally, thereflective profile 118 may include an electroformed nickel substrate forheat resistance.

Preferably the profile 118 is defined by a parabola having a focallength of less than 0.080 inches, and more preferably between0.020-0.050 inches. Further, the distance between the vertex of theparabola defining the profile 118 and the aft opening of the reflector118 is preferably 0.080-0.130 inches, more preferably 0.105-0.115inches. The opening of the forward end of the reflector 106 preferablyhas a diameter of 0.7-0.8 inches, more preferably 0.741-0.743 inches,and the opening of the aft end of the reflector 106 preferably has adiameter of 0.2-0.3 inches, more preferably 0.240 to 0.250 inches.Further, the ratio between the distance from the vertex to the openingof the aft end of the reflector 106 and the focal length is preferablyin the range of 1.5:1 and 6.5:1, more preferably 3.0:1 to 3.4:1.Moreover, the ratio between the distance from the vertex to the openingof the forward end of the reflector 106 and the focal length ispreferably in the range of 20:1 and 40:1, more preferably 26:1 to 31:1.

In the illustrated flashlight 10, the reflector 106 may be selectivelymoved in the axial direction relative to the light source 14. Byrotating the head assembly 20 relative to the barrel 12 the headassembly 20 travels along the forward threads 18 of the barrel 12 andcauses the reflector 106 to axially displace relative to the lightsource 14. By varying the axial position of the reflector 106 relativeto the light source 14, the flashlight 10 varies the dispersion of lightproduced by the light source 14. In this way, the flashlight 10 can beadjusted between spot and flood lighting.

Although the illustrated embodiment employs mating threads to enable themovement of the reflector 106 axially relative to the light source 14,in other embodiments other mechanisms may be employed to achieve anadjustable focus feature.

Further, because the head assembly 20 of the illustrated embodiment doesnot form part of the electrical circuit, it may be completely removedfrom the barrel 12 of the flashlight 10 so that the tail cap 28 end ofthe flashlight 10 may be inserted into the head assembly 20 and theflashlight used in a “candle mode.”

Referring back to FIG. 3, although the embodiment disclosed hereinillustrates a substantially planar lens 104, the flashlight 10 mayinstead include a lens that has curved surfaces to further improve theoptical performance of the flashlight 10. For example, the lens mayinclude a biconvex profile or a plano-convex profile in the whole orpart of the lens surface.

A sealing element, such as an O-ring 75, may also be incorporated at theinterface between the face cap 102 and the lens 104, the face cap 102and the head 108, and the head 108 and the barrel 12 to provide awatertight seal.

The electrical circuit of flashlight 10 will now be described. Referringto FIGS. 2-4, the electrical circuit of flashlight 10 is shown in theopen or OFF position. The electrical circuit is closed, or is in the ONposition, when the head assembly 20 is rotated to sufficiently translatethe lighting module 40 in the forward direction so that the flaredregion 78 of the heat sink housing 44 electrically couples with thecontact 21 of the barrel 12. Once the circuit is closed, electricalenergy is conducted from the rear battery 16 through its center contactwhich is in connection with the case electrode of the battery 16disposed forward thereof. Electrical energy is then conducted from theforward-most battery 16 to the compressible positive contact 54 of thelighting module 40. The electrical energy is then selectively conductedthrough the electronics on the second circuit board 58 through the upperpositive contact 74 and to the positive electrode of the light source 14via the first circuit board 38. After passing through the light source14, the electrical energy emerges through the negative electrode of thelight source 14 which is electrically coupled to heat sink 80 via thefirst circuit board 38. The heat sink housing 44 of heat sink 80 iselectrically coupled to the contact 21 of barrel 12. The barrel 12 iscoupled to the tail cap 28, which is in electrical contact with theconductive spring member 32. Finally, the conductive spring member 32 ofthe tail cap assembly 30 completes the circuit by electrically couplingwith the case electrode of the rearmost battery. In this manner, a mainpower circuit is formed to provide electrical energy to illuminate thelight source 14.

In the present embodiment, a parallel ground path is also formed fromthe second circuit board 58 to the heat sink housing 44 through upperground contacts attached to the upper end of the second circuit board 58and the first printed circuit board 38, which is in turn in electricalcontact with the heat sink 80. Thus, the controller provided on thesecond circuit board 58 may remain powered at all times when themechanical power switch 41 is closed, even if the electronics on thesecond circuit board 58 modulate the light source 14 on and off.

Referring to FIG. 3, to open the electrical circuit of flashlight 10,the user may twist or rotate the head assembly 20 to translate thelighting module 40 in the aft direction until the flared region 78 ofthe heat sink housing 44 separates from the contact 21 of the barrel 12.

Although the illustrated embodiment of flashlight 10 is turned ON bycausing the head assembly 20 to move away from the barrel and turned OFFby causing the head assembly 20 to axially translate toward the barrel12, through a simple reconfiguration of lighting module 40, theretaining collar 42, and the annular lip 21, the flashlight 10 could bemade to operate in the inverse order. In other words, so that axialmovement of the head assembly 20 away from the barrel 12 would cause theflashlight to turn OFF and axial movement of the head assembly 20 towardthe barrel 12 would cause it to turn ON.

Further, although a rotating type mechanical power switch that opens andcloses the electrical circuit at the barrel/heat sink housing has beendescribed, the electrical circuit may be closed or opened at otherlocations. Moreover, although a rotating type mechanical power switchhas been described, the various aspects of the invention as describedherein are not limited by the type of mechanical power switch employed.Other suitable mechanical power switches, including, for example,push-button and sliding type mechanical power switches may also beemployed.

The multi-mode operation of flashlight 10 will now be described. Theflashlight 10 is preferably provided with a plurality of modes ofoperation. In the embodiment described below, the flashlight 10 isprovided with four modes of operation. Each mode of operation allows theflashlight 10 to perform one of four specific features of the flashlight10, such as, for example, normal operation, power save, blink, or SOS.When the flashlight 10 is initially turned ON, or if flashlight 10 hasbeen turned OFF for more than a predetermined period of time, theflashlight 10 will automatically operate in a first, default mode ofoperation. While the flashlight 10 is in the first operating mode, if itis turned OFF for a period of time, which is less than or equal to apredetermined period of time, and then turned back ON, the flashlight 10will change to a second operating mode. While the flashlight 10 is inthe second operating mode, if it is again turned OFF for a period oftime, which is less than or equal to a predetermined period of time, andthen turned back ON, the flashlight 10 will change to a third operatingmode. In the same manner, while the flashlight 10 is in the thirdoperating mode, if it is again turned OFF for another period of time,which is less than or equal to a predetermined period of time, and thenturned back ON, the flashlight 10 will change to a fourth operatingmode.

In the present embodiment, the predetermined period of time is set to beequal to one and a half (1.5) seconds, which is a relatively shortperiod of time, but more than sufficient for an operator of flashlight10 to manipulate the head assembly 20 to turn OFF flashlight 10 and thenturn flashlight 10 back ON. In other embodiments, a shorter or longerperiod may be desirable. However, the predetermined period is preferablyless than 3 seconds, otherwise flashlight 10 will have to sit idle toolong for the average user before it can be returned to its default modeof operation without indexing through all of the modes of operation.

In the embodiment described above, while the flashlight 10 is in thefourth operating mode, if it is turned OFF for a short period of timeand then turned back ON, the flashlight 10 will change back to the firstoperating mode. Yet in an embodiment with more than four modes ofoperation, if the flashlight 10 is turned OFF for a period of time thatis less than or equal to the predetermined period of time and thenturned back ON, the flashlight 10 will change to a fifth operating mode,and so on. Regardless of the number of included modes of operation,e.g., 2 to N, the flashlight 10 preferably cycles back to the first modeof operation after reaching the last mode programmed into theelectronics of the flashlight.

Preferably, the first operating mode is a normal mode in which the lightsource 14 of flashlight 10 is provided with maximum power as long as themechanical power switch 41 remains closed. The second operating mode inthe present embodiment is a power saving mode in which the light source14 of flashlight 10 is operated at reduced power (e.g., 50% power) inorder to extend the life of the batteries. The third operating mode ofthe present embodiment is a blink mode in which the light source 14 isflashed on and off at a predefined frequency or preprogrammed frequencypattern that is perceptible to the human eye. The fourth operating modeis an SOS mode in which the light source 14 is automatically flashed tosignal SOS in Morse code.

FIG. 6 is one embodiment of a circuit diagram for the flashlight 10 ofFIG. 1. In the embodiment of FIG. 6, the circuit for the flashlight 10of FIG. 1 includes batteries 16, electronic switch 117, light source 14,mechanical power switch 41, controller 140, and state machine 150. Inthe illustrated embodiment, the light source 14 is an LED. In otherembodiments, the light source 14 may be incandescent lamp or arc lamp.

The mechanical power switch 41 in the present embodiment corresponds tothe mechanical power switch formed by lighting module 40, retainingcollar 42, barrel 12, and head assembly 20. As illustrated, the contactsof mechanical power switch 41 in the present embodiment comprise heatsink housing 44 and contact 21 of barrel 12.

The controller 140 is preferably a microcontroller, such as, forexample, ATtiny 13 which is an 8-bit microcontroller manufactured byAtmel Corporation of San Jose, Calif. In other embodiments, thecontroller 140 may be a microprocessor, an ASIC, or discrete components.

In the present embodiment, the batteries 16 are arranged electrically inseries so that there is a positive electrode 122 and a negativeelectrode 124, with the positive electrode 122 corresponding to thepositive electrode of the front-most battery and the negative electrode124 corresponding to the negative electrode of the rear-most battery. Inother embodiments, the batteries may be arranged electrically inparallel.

The electronic switch 117 has a voltage input 126, a voltage output 128and a duty cycle input 131. The light source 14 has a first, positiveelectrode 58 and a second, negative electrode 59. The mechanical powerswitch 41 includes heat sink housing 44 as a first, contact and contact21 of barrel 12 as a second contact. The controller 140 has a powerinput 146, a ground 148, a plurality of data ports 142, 144 and a dutycycle output 130. The state machine 150 has a plurality of state ports182, 184 and a ground connection 156.

In the present embodiment, the positive electrode 122 of the batteries16 is electrically coupled to the voltage input 126 of the electronicswitch 117 and the power supply input 146 of the controller 140. Thevoltage output 128 of the electronic switch 117 is electrically coupledto the first, positive electrode 58 of the light source 14. The second,negative electrode 59 of the light source 14 is electrically coupled tothe first contact (heat sink housing 44 in the present embodiment) ofthe mechanical power switch 41. Therefore, when the second contact(contact 21 of barrel 12) of mechanical power switch 41 is brought intocontact with the first contact, so that the mechanical switch 41 isclosed, a first closed circuit loop (corresponding to the main powercircuit of flashlight 10) is formed in which electric current flows fromthe batteries 16, through the electronic switch 117, the light source14, and the mechanical power switch 41.

The electronic switch 117 and the light source 14 are considered theload of the first closed circuit loop. When the switch 41 is open, theload is electrically disconnected from the batteries 16.

In one embodiment, the electronic switch 117 is a power transistor,preferably a p-channel MOSFET, since switching is being performed on thehigh-side in the circuit of the present embodiment. In an embodiment inwhich switching is performed on the low-side of the circuit, then ann-channel MOSFET would be desirable. In still another embodiment,electronic switch 117 may be a load switch including a current-limitedp-channel MOSFET, such as the FPF 2165 manufactured by FairchildSemiconductor. A current-limited load switch may provide downstreamprotection to systems and loads which may encounter large currentconditions. For example, it may be desirable to use such a load switchif the flashlight embodiment includes three or more batteries 16 inseries.

In the present embodiment, the positive electrode 122 of the batteries16 is also connected to the power input 146 of the controller 140. Theground 148 of the controller 140 connects to the first contact of themechanical power switch 41. Therefore, when mechanical power switch 41is closed, a second closed circuit loop is also formed in which anelectric current flows from the batteries 16, through the controller140, and the mechanical power switch 41. The controller 140 isconsidered the load of the second closed circuit loop. When themechanical power switch 41 is open, the load of the second loop, namelythe controller, is electrically disconnected from the batteries 16.

Accordingly, as shown in FIG. 6, the main power circuit includes amechanical power switch 41 and an electronic switch 117 disposedelectrically in series with the light source 14. Further, controller 140is electrically coupled in series with the mechanical power switch 41 sothat when the mechanical power switch 41 is opened, the controller 140is not powered by the batteries 16. The controller 141 includes anoutput 130 for providing a control signal for controlling the openingand closing of the electronic switch 117. The controller is alsoconfigured to control the electronic switch 117 in a manner to provideat least two modes of operation as discussed below.

The state machine 150 comprises a memory mechanism for temporarilystoring a mode of operation. It includes at least one output (e.g.,outputs 182 and 184) coupled to the controller 140 for communicating atleast one output signal to the controller 140. As discussed in moredetail below, the controller 140 is configured to determine the mode ofoperation based on the at least one output signal from the state machine150. The controller 140 also writes a new mode of operation to the statemachine 150 following power up.

In the present embodiment, the electronic switch 117, the controller140, and the state machine 150 all reside on second circuit board 58 ofthe lighting module 40. In other embodiments, they may reside onseparate circuit boards, and may reside in locations other than thelighting module 40.

In the present embodiment, the mechanical power switch 41 is used as theuser interface for the multi-mode flashlight 10 in addition to servingas the main power switch. Accordingly, the controller 140 is required tointerpret the actuations of the mechanical power switch 41 as inputsfrom the user and change the operational mode of flashlight 10accordingly.

Because the load 117, 14, 140, and in particular the controller 140, isun-powered every time the switch 41 is in the OFF position, when switch41 is once again closed to turn the flashlight 10 ON, the controller 140has no intrinsic way of knowing what state or mode the flashlight 10 wasin the last time the mechanical power switch 41 was closed. Accordingly,the state machine 150 is used to provide state information of theflashlight 10 to the controller 140 every time flashlight 10 is turnedON by mechanical power switch 41.

FIG. 7 is a circuit diagram showing one embodiment of a state machine150 for the flashlight 10 of FIG. 1. In the embodiment of FIG. 7, two RCtiming circuits are used. One is shown on the left of state machine 150and the other is shown on the right of state machine 150. The left RCcircuit includes a capacitor 152 electrically coupled in parallel to ableed off resistor 162. A charging resistor 172 is interposed betweenthe parallel RC circuit 152, 162 and the state port 182 of the statemachine 150. The resistor 172 is also connected in series with the RCcircuit 152, 162. The state port 182 is electrically coupled to the dataport 142 of the controller 140.

The configuration of the right RC circuit is similar to the left RCcircuit. A capacitor 154 is electrically coupled in parallel to a bleedoff resistor 164. A charging resistor 174 is electrically interposedbetween the parallel RC circuit 154, 164 and the state port 184 and isin series with the RC circuit 154, 164. The state port 184 is furthercoupled to the data port 144 of the controller 140. Both RC circuits152, 162 and 154, 164 are coupled to ground connection 156, which isfurther coupled to the first contact (heat sink housing 44) of themechanical power switch 41.

The capacitance of capacitors 152, 154 and the resistors 162, 164 arepreferably selected so as to provide a time constant of greater thanabout 3 seconds and less than about 4 seconds. For example, in oneembodiment, the capacitance of the capacitors 152, 154 is set at 2.2 uF,and the resistance of the bleed off resistors 162, 164 is set at 1.5 MΩ.As a result, the nominal time constant (τ) for each parallel RC circuitis equal to 3.3 seconds (2.2 uF×1.5 MΩ). This time constant representsthe time for each of the capacitors 152, 154 to decay to 37% of theircharged voltage value. Thus, if the fully charged voltage on each of thecapacitors 152, 154 is three (3) volts before the flashlight 10 isturned OFF, the voltage on each of the capacitors 152, 154 would beapproximately 1.11 volts after the time constant of 3.3 seconds iselapsed. By contrast, the resistance of charging resistors 172, 174 ispreferably set very low (e.g. 10 kΩ) so that the time constants (τ) ofthe RC circuits 172, 152 and 174, 154 is very short (e.g. 22 ms), sothat the capacitors 152 and 154 can be fully charged by controller 140almost instantaneously (e.g., 110 ms in the present embodiment). Ingeneral the resistance of charging resistors 172, 174 should be set sothat capacitors 152, 154 are charged in a period of time that issubstantially shorter than it would take a user to turn ON and then OFFflashlight 10 during normal operation. In general, the bleed offresistor preferably has a resistance of at least two orders of magnitudegreater than the charge resistor.

When the mechanical power switch 41 is opened or in the OFF position,the voltage stored on capacitors 152, 154 will decay at a given ratethat is dependent on the value of the capacitor 152, 154 and bleed offresistors 162, 164, respectively. When the mechanical power switch 41 isclosed so that the flashlight 10 is turned back ON, there will be aresidual voltage remaining across each of capacitors 152, 154. Theresidual voltage on each capacitor 152, 154 is measured by thecontroller 140 upon power up when the mechanical power switch 41 isclosed. The controller 140 interprets the residual voltage remaining oneach capacitor 152, 154 as an ON or an OFF (i.e., as a 1 or a 0),depending on the voltage it measures for each capacitor. Based on theinterpreted state of each capacitor, the controller 140 determines andimplements the appropriate mode of operation for flashlight 10. Table 1below, summarizes each operational mode the controller 140 of thepresent embodiment is configured to implement based on the state of eachcapacitor 152, 154 at the time the controller 140 is powered up. Inother embodiments, other modes may be included or the modes may beassociated with different states of capacitors 152, 154.

TABLE 1 Summary of operating modes and voltage values on capacitors C1and C2. Voltage Value Present At Voltage Value Set After Power Turn ONPower Turn ON (current mode) (next mode) Mode C1 (152) C2 (154) C1 (152)C2 (154) Normal 0 0 0 1 Power Save 0 1 1 0 Blink 1 0 1 1 SOS 1 1 0 0

As can be seen from the foregoing, controller 140 can readily use theresidual voltage stored on capacitors 152, 154 to determine theoperational mode of the flashlight 10 each time the controller 140 ispowered up. Further, as shown in Table 1, using two parallel RC circuits(152, 162 and 154, 164) allows four modes of operation. More modes canbe implemented by using more parallel RC circuits. Because eachcapacitor can be used to represent two logic values, the number ofavailable operating modes can be 2^(n), wherein n is the number ofparallel RC circuits. For example, one RC circuit yields a maximum oftwo operating modes, two RC circuits yields a maximum of four operatingmodes, and three RC circuits yields a maximum of eight operating modes,etc.

Beneficially, if the mechanical power switch 41 is left open or in theOFF position for a sufficient period of time, the residual voltageacross capacitors 152, 154 will decay to zero (0) volts, regardless oftheir original state. As a result, when the controller 140 is turned onagain, the controller 140 will measure no voltage on either capacitor152 or 154 and, as shown in Table 1, put the flashlight 10 into thefirst or “Normal” mode of operation.

How controller 140 interprets the residual voltage remaining on eachcapacitor 152, 154 as being in the ON or OFF state (i.e., as a 1 or a 0)is now explained. In one embodiment, the residual voltage remaining oneach capacitors 152 and 154 at power up is measured by ananalog-to-digital converter (ADC) which is embedded in the controller140. The measured voltages are then compared against a voltage stored innon-volatile memory. If the measured voltage is equal to or greater thanthe voltage stored in memory for the capacitor, then the capacitor istreated as being in the ON state, whereas if the measured voltage for acapacitor is less than the stored voltage for the capacitor, it istreated as being in the OFF state. The voltage stored in memory for eachcapacitor 152, 154 may, for example, correspond to what the residualvoltage across each capacitor should be after a predetermined timethreshold has lapsed from the opening of mechanical power switch 41, forexample, 1.5 seconds. This means that if the user wants to switch fromthe normal mode to power save mode, he/she would be able to turn theflashlight 10 off for up to 1.5 seconds before turning it back on, andthe flashlight will change to the power save mode. Any longer time wouldcause the flashlight to return to the normal mode.

While the decay voltage value stored in non-volatile memory for eachcapacitor 152, 154 may be calculated based on the decay formulaV_(c)=Ee^(−t/τ), a more preferred approach is to empirically determinethe voltage stored on each capacitor 152, 154 after the desiredpredetermined period has lapsed and then store the residual value forthat capacitor in non-volatile memory for the future reference ofcontroller 140.

Because the manufacturing tolerances for capacitors is relatively high,the actual capacitance of a capacitor can vary significantly from itsnominal value, as well as from the actual capacitance of anothercapacitor having the same nominal capacitance. As a result, capacitorswith the same nominal capacitance can discharge at substantiallydifferent rates during bleed off, with higher capacitance capacitorstaking longer to drain than lower capacitance capacitors. In order toremove such variability from the system, in a preferred embodiment, acalibration procedure is performed during manufacturing to normalize orcalibrate the discharge rate of each capacitor 152, 154. A detaileddescription of an embodiment of the calibration procedure is describedbelow.

Once second circuit board 58 is manufactured, the board is connected toan LED to simulate the load of the flashlight 10 while the relevant pinof the controller is driven low to provide a calibration signal to thecontroller. The controller and load are then powered and both capacitors152, 154 fully charged. Power to the controller 140 and LED is then cutoff for an exact interval, for example, 1.5 seconds. After the set timeinterval has passed, the circuit is powered up and the voltage value oneach capacitors 152, 154 is precisely measured by the controller 140,which then stores the measured voltage values for each capacitor innon-volatile memory, such as an EEPROM embedded in the controller 140.The voltage value stored in non-volatile memory for each capacitors 152,154 now precisely reflects the decay voltage threshold for eachcapacitor after the predetermined period (e.g., 1.5 seconds) has lapsed.This procedure thus removes the effects of capacitor tolerance thatcould affect the on/off timing of the multiple flashlight modes.

The predetermined period is preferably greater than or equal to 0.75second and less than or equal to 3.0 seconds. More preferably, thepredetermined period is greater than or equal to 1.0 second and lessthan or equal to 2.0 seconds. Still more preferably, the predeterminedperiod is 1.5 seconds.

The operation of the flashlight 10 between different modes will now bedescribed in connection with Table 1 and FIG. 7. When the flashlight 10is initially turned ON or turned ON after 1.5 seconds has lapsed, theflashlight 10 is operated in a normal mode. The controller 140 thencharges capacitor C2 154 through the charging resistor 174 by pulling upthe data port 144. For example, if the flashlight includes 3 batteriesin series, the voltage across capacitor 152 will be approximately 4.5volts, whereas if the flashlight 10 only includes two batteries then thevoltage across capacitor 154 will be approximately 3.0 volts.Simultaneously, the controller 10 discharges capacitor C1 152 by pullingdown the data port 142 and consequently, the voltage across capacitor C1152 will be approaching 0 volts. As shown in the two right-most columnsof Table 1, the logic value of capacitor C1 152 is set to 0 and thelogic value of capacitor C2 154 is set to 1. In the illustratedembodiment, the value of charging resistors 172, 174 are preferably setat 10 KΩ or less so that capacitors 152, 154 can be fully charged inabout 50 ms or less.

While the flashlight 10 is in the Normal mode, if it is turned OFF forless than, for example, 1.5 seconds and then turned back ON, the voltagevalue measured at data port 142 will be approaching 0 volts and thevoltage value measured at data port 144 will be higher than the 1.5second voltage threshold value stored in the non-volatile memory. Thecontroller 140 compares the voltage values presented at data ports 142,144 to the corresponding values in memory and determines that thecorrect mode of operation is now the second mode, which is a power savemode. The controller 140 then charges capacitor C1 152 and dischargescapacitor C2 154 using the method described in the normal mode. As shownin Table 1, the logic value of capacitor C1 152 is set to 1 and thelogic value of capacitor C2 154 is set to 0.

While the flashlight 10 is in the power save mode, if it is turned OFFfor less than, for example, 1.5 seconds and then turned back ON, thevoltage value measured at data port 144 will be approaching 0 volts andthe voltage value measured at data port 142 will be higher than the 1.5seconds voltage threshold value stored in the non-volatile memory. Thecontroller 140 compares the voltage values presented at data ports 142,144 to the corresponding values in memory and determines that thecorrect mode of operation is now the third mode, which is a blink mode.The controller 140 then charges both capacitors C1 152 and C2 154. Asshown in Table 1, the logic value of capacitors C1 152 and C2 154 areboth 1. While the flashlight 10 is in the Blink mode, the light sourcevisibly blinks ON and OFF at a frequency stored in the controller 140.

While the flashlight 10 is in the Blink mode, if it is turned OFF forless than, for example, 1.5 seconds and then turned back ON, the voltagevalue measured at both data ports 142 and 144 will be higher than eachof their corresponding 1.5 seconds voltage threshold values stored inthe non-volatile memory. The controller 140 compares the voltage valuespresented at data ports 142, 144 to the corresponding values in memoryand determines the correct mode of operation is now a fourth mode, whichis an SOS mode. The controller 140 then discharge both capacitors C1 152and C2 154. As shown in Table 1, the logic value of capacitors C1 152and C2 154 are both 0.

As reflected by Table 1, the above process may continue indefinitelywhile the user indexes through the various modes of operation programmedinto the controller 140.

In the embodiment illustrated in FIG. 7, RC circuits 152, 162 and 154,164 are used as the temporary memory means or devices state machine 150for memorizing the next mode of operation that controller 140 is toimplement at power up. In other embodiments, energy storage devicesother than capacitors 152 and 154 may be used. For example, inductorsmay be used in parallel with the bleed off resistors 162, 164 instead ofcapacitors 152, 154 to form RL circuits as the temporary energy storagemeans or devices. In this manner an LC timing circuit would be connectedto data ports 142, 144.

If flashlight 10 is configured to hold 3 batteries 16 in series, theelectronic switch 117 preferably comprises a current-limited load switchto regulate the current provided to light source 14 to a desired level,particularly if light source 14 comprises an LED. Preferably, theelectronic switch 117 modulates the DC current from the batteries 16 toa pulsed current. The current limited switch can be a commercial devicesuch as FPF2165 manufactured by Fairchild Semiconductor. The outputcurrent delivered to the light source 14 can be set by a resistorconnected to the ISET pin of the current-limited switch. However,because current-limited load switches of this type have a higher thandesired tolerance (e.g., ±25%), if the output current for the switch isset per design requirements to 500 mA, for example, and the switch has atolerance of ±25%, the actual range of possible output currents for theload switch would be between 375 mA and 625 mA. The manufacturingtolerance of the current-limited load switch would, therefore, produceundesirable intensity differences from flashlight to flashlight.

To minimize light to light fluctuations, the following procedure may beemployed to calibrate or normalize the output of the electronic switch117. First, the ISET resistor for the current-limited load switch may beselected based on a minimum output current desired to be output fromelectronic switch 117 and delivered to the light source 14. Because ofthe wide manufacturing tolerances of the current-limited devices, allmost all of the devices will actually output a current above the desiredoutput current limit unless modulated. Accordingly, the controller 140is configured to control the port 130, and hence the duty cycle input131 of the electronic switch 117, using a pulse-width modulation (PWM)signal. By adjusting the duty cycle of this PWM signal, the averageoutput current from the electronic switch 117 can be controlled to thedesired level.

The duty cycle the controller uses to control the average output currentof the current-limited electronic switch 117 to the desired level isstored in non-volatile memory, such an EEPROM embedded in thecontroller. During the calibration procedure, the initial duty cyclevalue stored in memory is set at 100% and is then decremented during afunctional test until the appropriate duty cycle is reached to producethe desired average output current from the electronic switch 117. Inone embodiment, the duty cycle of the current-limited electronic switch117 is decremented until the electronic switch delivers an outputcurrent of 525 mA to the light source 14. Once the desired averagecurrent is achieved, the duty cycle resulting in the desired averagecurrent is stored back in the non-volatile memory of the controller 114so that the light source 14 will always operate at that maximum dutycycle during the different modes of operation, with the exception of thepower save mode. In the power save mode, the duty cycle is furtherdecremented to result in the desired power savings from the “Normal”mode (e.g., 25% or 50%).

In the foregoing discussion, a current-limited load switch was employedas electronic switch 117 to limit the current delivered to light source14. In other embodiments, in which it is desired to increase or decreasethe current provided by the batteries 16 or other portable source ofpower to the light source 14, as shown in FIG. 8, a current regulatingcircuit 160 may be electrically interposed between the output fromelectronic switch 117 and the light source 114. Depending on the designrequirements, current regulating circuit 160 may be a conventional boostconverter, buck converter, or boost/buck converter.

FIG. 9 illustrates a circuit diagram for a regulating circuit 160comprising a boost converter 162 for boosting the average currentdelivered to light source 14 from, for example, two batteries 16connected in series. The boost converter circuit includes a microchip163, a switching transistor 164, an inductor 165 disposed in series withthe electronic switch 117 and light source 14, and a current senseresistor 166 connected in series with the emitter of the switchingtransistor 164. Capacitors 167, 168 are also provided in the presentembodiment between the Vcc pin and the STDN pin and ground for themicrochip 163. This is done to limit the voltage drop on the inputsupply caused by transient in-rush current when the inductor 165 ischarging. In the boost converter circuit 162 shown in FIG. 9 lightsource 14 is supplied with a pulsed current to maximize battery life. Inother embodiments, the boost converter may be arranged in a conventionalmanner to provide a constant current to maximize brightness of lightsource 14. In one embodiment, microchip 163 preferably comprises aZXSC310E5 by Zetex Semiconductors. Switching transistor 163 ispreferably a bipolar transistor, but may also comprise other switchingtransistors. Other boost converter circuits may also be employed,including boost circuits that provide a continuous DC current output tothe light source 14.

While various embodiments of an improved flashlight and its respectivecomponents have been presented in the foregoing disclosure, numerousmodifications, alterations, alternate embodiments, and alternatematerials may be contemplated by those skilled in the art and may beutilized in accomplishing the various aspects of the present invention.Thus, it is to be clearly understood that this description is made onlyby way of example and not as a limitation on the scope of the inventionas claimed below.

1. A multi-mode portable lighting device comprising: a housing forreceiving a portable power source having a positive electrode and anegative electrode; a light source having a first electrode and a secondelectrode; a main power circuit for connecting the first and secondelectrodes of the light source to the positive and negative electrodesof the portable power source, respectively, the main power circuitincluding a mechanical power switch and an electronic power switchdisposed electrically in series with the light source; a controllerelectrically coupled in series with the mechanical power switch so thatwhen the mechanical power switch is opened, the controller is notpowered by the portable power source, the controller including an outputfor providing a control signal for controlling the opening and closingof the electronic power switch, the controller being configured tocontrol the electronic power switch in a manner to provide at least twomodes of operation; a state machine having a memory mechanism fortemporarily storing a mode of operation and at least one output coupledto the controller for communicating at least one output signal to thecontroller, wherein said controller is configured to determine the modeof operation based on the at least one output signal from the statemachine, and wherein the controller is configured to write a new mode ofoperation to the state machine following power up.
 2. A multi-modeportable lighting device according to claim 1, wherein said controlleris a microcontroller.
 3. A multi-mode portable lighting device accordingto claim 1, wherein said controller is configured to determine the modeof operation based on the at least one output signal from the statemachine by reading a voltage on each output signal from the statemachine and comparing that voltage to information stored in non-volatilememory.
 4. A multi-mode portable lighting device according to claim 3,wherein the state machine comprises at least one energy storage devicein parallel with a bleed off resistor.
 5. A multi-mode portable lightingdevice according to claim 4, wherein the energy storage device is acapacitor.
 6. A multi-mode portable lighting device according to claim4, wherein the energy storage device is an inductor.
 7. A multi-modeportable lighting device according to claim 3, wherein said non-volatilememory is an EEPROM.
 8. A multi-mode portable lighting device accordingto claim 7, wherein said controller is a microcontroller and said EEPROMis embedded in said microcontroller.
 9. A multi-mode portable lightingdevice according to claim 1, further comprising an analog-to-digitalconverter.
 10. A multi-mode portable lighting device according to claim9, wherein said analog-to-digital converter is embedded in saidcontroller.
 11. A multi-mode portable lighting device according to claim1, wherein the light source is an LED.
 12. A multi-mode portablelighting device according to claim 1, wherein the light source includesa filament.
 13. A multi-mode portable lighting device according to claim1 wherein the state machine includes a first RC circuit having acapacitor and a bleed off resistor electrically connected to thecapacitor in parallel.
 14. A multi-mode portable lighting deviceaccording to claim 13, wherein the state machine further includes acharge resistor electrically disposed in series between a data port ofthe controller and the first RC circuit.
 15. A multi-mode portablelighting device according to claim 14, wherein the resistance of thecharge resistor is substantially less than the resistance of the bleedoff resistor.
 16. A multi-mode portable lighting device according toclaim 15, wherein the bleed off resistor has a resistance of at leasttwo orders of magnitude greater than the charge resistor.
 17. Amulti-mode portable lighting device according to claim 1, wherein thestate machine includes two state outputs connected to the controller,and the controller is configured to control the electronic power switchin a manner to provide four modes of operation.
 18. A multi-modeportable lighting device according to claim 1, wherein said operatingmodes include a normal mode and a power reduction mode.
 19. A multi-modeportable lighting device according to claim 1, wherein said operatingmodes include a normal mode and an SOS mode.
 20. A multi-mode portablelighting device according to claim 1, wherein said operating modesinclude a normal mode and a blink mode.
 21. A multi-mode portablelighting device according to claim 1, wherein said state machine storesa mode of operation for greater than or equal to 0.75 seconds and lessthan and less than 3 seconds.
 22. A multi-mode portable lighting deviceaccording to claim 1, wherein said state machine stores a mode ofoperation for greater than or equal to 1.0 second and less than or equalto 2.0 seconds.
 23. A multi-mode portable lighting device according toclaim 1, wherein said state machine stores a mode of operation for about1.5 seconds.
 24. A method of operating a multi-mode portable lightingdevice including a main power circuit for connecting a light source to aportable power source, a controller for controlling an electronic powerswitch disposed in the main power circuit in electrical series with thelight source, the controller being electrically connected in series to amechanical power switch disposed in the main power circuit in serieswith the light source and which acts as the user interface to thecontroller, the method comprising the steps of: using the controllerupon power up to read at least one output signal from a state machine todetermine a first mode of operation based on the least one outputsignal; writing a second mode of operation from the controller to thestate machine following power up, wherein the state machine willremember the second mode of operation for a brief period after themechanical power switch is opened so that if the mechanical power switchis closed before the brief period lapses, the controller will operate inthe second mode of operation.
 25. A method of calibrating one or morememory capacitors of a driver circuit for a multi-mode portable lightingdevice, wherein each memory capacitor is connected to a data port of acontroller in parallel with a bleed off resistor, the method comprising:powering the driver circuit to charge each of the one or more memorycapacitors; removing the power from the driver circuit for apredetermined time interval; powering the driver circuit as soon as thepredetermined time interval has lapsed; measuring the voltage value oneach of the one or more memory capacitors; and storing the voltagemeasured for each of the one or more memory capacitors in a non-volatilememory accessible by the controller.
 26. The method of claim 25, whereinthe brief period of time is less than or equal to 1.5 seconds.